Hinged Flap Cover With Angled Seal For Electric Vehicle Charging Inlet
A charging inlet for an electric vehicle (EV) includes a body defining an opening having a conductive terminal arranged therein. A sealing cover is pivotally attached to the body and is moveable between an open position exposing the opening and conductive terminal, and a closed position sealing the opening and the conductive terminal with respect to an external environment. A sealing element of the cover defines a sealing plug including an angled sealing rib defined about an outer periphery thereof. The sealing plug and sealing rib are configured to engage with the opening of inlet body for sealing the opening with the cover in the closed position.
Latest TE Connectivity Services GmbH Patents:
The present disclosure relates to electric vehicle (EV) charging receptacles or inlets, and more specifically, to improved systems for selectively sealing the conductive terminals of an EV charging inlet.
BACKGROUNDElectric vehicles (EVs) are increasing in popularity as their practicality and usability improves. In order to fulfill consumer performance demands for both personal and commercial applications, these still-early systems must to continuously optimized to extract maximum performance, usability and convenience. One critical aspect of EV usability includes the ability to consistently charge the batteries of an EV as quickly as possible over the life of the vehicle. In this way, it is desired to minimize any degradations in charging performance. Charging performance can be affected by any number of factors, including moisture, dirt and other debris contaminating and/or degrading the electrical terminals or contacts of the charger plug or the socket/receptacle of the EV. Accordingly, it is desired to shield these sensitive surfaces from the outside environment whenever possible.
This desire has resulted in, for example, the implementation of covers arranged over the charging socket(s) of the inlet, which may be removed during charging operations to expose the socket and permit plug engagement therewith. These covers, however, have proven ineffective against the long-term buildup of contaminants on the receptacles, and moreover, are unnecessarily bulky, complex and/or expensive to manufacture. By way of further example, many of today's EVs are fitted with combined charging systems (CCSs), or systems which permit both traditional AC-based charging, as well as DC-based “fast” charging. However, each of these charging systems necessitates the use of its own plug configuration, for example, a Type 1 or Type 2 connection for AC charging, and a second two-pin DC connector for fast charging operations. Accordingly, modern interface standards include so-called combination configurations which include a Type 1 connector or a Type 2 connector, as well as a two-pin DC connector, arranged together on a single inlet. In use, however, depending on the type of charging plug being used, a vehicle being charged with its AC charging system, and thus its Type 1 or Type 2 connector fitted with a corresponding plug, may leave the two-pin DC connectors exposed, or vise-versa, during the charging operation. During charging, the unused portion of the socket is exposed to dirt, dust, moisture (e.g., rain) and other unwanted debris. Likewise, vehicles may be subject to severe use, including prolonged exposure to significant moisture such as when crossing a waterway during off-road use, or when subject to flooding conditions. Such exposures can negatively affect charging performance as contaminants are built up over the life of the vehicle, or may more immediately impact the reliability of the vehicle in the case of submersion. As set forth above, prior art covers have proven inadequate in preventing the build-up of debris and/or sealing these types of connectors under all conditions.
Accordingly, there is a need for improved systems and methods for sealing the charging inlet.
SUMMARYIn one embodiment of the present disclosure a charging inlet for an electric vehicle (EV) having a terminal sealing cover is provided. The inlet includes a body defining an opening having a conductive terminal arranged therein. The sealing cover is pivotally attached to the body and moveable between an open position, exposing the opening and the conductive terminal, and a closed position, sealing the opening and the conductive terminal with respect to the external environment. A sealing element defining a sealing plug extends from the cover and includes an angled sealing rib formed about an outer periphery thereof. The sealing rib is configured to sealingly engage with the opening for sealing the opening with the cover in the closed position.
According to another embodiment of the present disclosure, a sealing cover for an EV charging inlet is provided. The cover includes a body having a mounting end configured to pivotally mount to the charging inlet. A sealing element is received within a seal receiving space of the cover and comprises at least one sealing plug extending from a base thereof. The sealing plug includes an angled sealing rib extending about an outer periphery thereof in a non-coaxial orientation. The sealing rib and sealing plug are configured to sealingly engage with a terminal opening of the charging inlet with the cover in a closed position.
The invention will now be described by way of example with reference to the accompanying Figures, of which:
Exemplary embodiments of the present disclosure will be described hereinafter in detail with reference to the attached drawings, wherein like reference numerals refer to like elements. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that the present disclosure will convey the concept of the disclosure to those skilled in the art. In addition, in the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it is apparent that one or more embodiments may also be implemented without these specific details.
Embodiments of the present disclosure include improved covers for sealing one or more sockets of an EV charging inlet. In one embodiment, the cover is moveably (e.g., pivotally) mounted to a housing, and moveable or rotatable between a closed position and an open or charging position. The cover includes at least one sealing element sized to engage an opening of the inlet in a sealing manner. The sealing element includes a sealing rib adapted to engage with or contact a sidewall of the opening of the inlet for generating a seal therewith. The sealing rib is angled such that, as the cover is rotated into the closed position, the sealing rib engages or contacts the end of the opening simultaneously about its entire periphery, despite being introduced into the opening in an angular manner (i.e., not introduced or inserted along an axis of the opening). In one embodiment, the cover is specifically configured to seal two-pin openings associated with a DC charging socket of a combination charging receptacle. In this way, these openings remained sealed from dust and other debris, during charging of the vehicle via the AC socket.
Referring to
Referring generally to
As is more clearly shown in
Referring again to
Still referring to
The sealing rib 228 is angled such that the portion of the sealing rib closest to the base 222 of the sealing element 220 in the axial direction of the sealing plug 224 is positioned closest or most proximate to the pivoting axis of the mounting portion 204 of the cover 200. Likewise, the portion of the sealing rib 228 furthest from the base 222 in the axial direction of the sealing plug 224 is positioned most distally or furthest from pivoting axis of the mounting portion 20 or hinged connection, or on a portion of the diameter of the cylindrical portion opposite the hinged side of the cover. In this way, the predetermined angle α defined between the axis of the sealing plug 224 and the axis of the sealing rib 228 is such that as the cover 200 is moved from an open position to a closed position along an arcuate path, the sealing rib contacts the wall 118 of the socket 114 generally simultaneously about its entire circumference or perimeter, despite the sealing element 220 or plug 224 being introduced into the socket at an angle. As shown most clearly in
This arrangement provides numerous benefits over prior art arrangements. Specifically, the angled sealing rib 228 enables contemporaneous and uniform compression of the sealing rib against the socket wall 118 during the insertion or closing operation. This improves sealing characteristics, as well as seal life by more uniformly distributing forces, and preventing excess deformation of each sealing plug 224 and rib 228 as they are introduced into the corresponding openings 120. Further, this arrangement prevents incomplete or incidental partial closures of the cover 200, as well as offers a tactile improvement to a user, as the force to fully compress the sealing rib 228 into frictional engagement with the aperture 120 is more clearly discernable.
In the closed or installed state shown in
While the cover 200 and associated sealing element 220 are described throughout as being attached to a bottom of the inlet housing 102, it should be understood that embodiments of the present disclosure include covers attachable to any side, or in any relative orientation, to the inlet or socket which they are configured to cover. Likewise, embodiments have been described herein as applied to a cover for a DC charging socket. However, it should be understood that covers described herein may be adapted to be used for any type of charging port or socket, without departing from the scope of the present disclosure. For example, a similar cover having angled sealing features according to embodiments of the preset disclosure may be adapted for use with the first or AC-type sockets in addition to the DC charging socket.
The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range.
Also, the indefinite articles “a” and “an” preceding an element or component of the invention are intended to be nonrestrictive regarding the number of instances, that is, occurrences of the element or component. Therefore “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.
The term “invention” or “present invention” as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the application.
Claims
1. A charging inlet, comprising:
- a body defining an opening having a conductive terminal arranged therein;
- a sealing cover attached to the body and moveable between an open position, wherein the conductive terminal is exposed, and a closed position, wherein the opening and the conductive terminal are sealed with respect to the external environment, the cover including a sealing element extending from the cover and having a sealing rib formed about an outer periphery thereof for engaging with an interior sidewall of the opening.
2. The charging inlet of claim 1, wherein the sealing cover is moved between the open position and the closed position along an arcuate path.
3. The charging inlet of claim 2, wherein the sealing rib is oriented at an angle with respect to an exterior surface of the sealing element.
4. The charging inlet of claim 3, wherein the sealing element defines a sealing plug, and wherein the sealing rib comprises an annular rib defined about a central axis that is not coaxial with a central axis of the plug.
5. The charging inlet of claim 4, wherein the body defines a pair of DC charging terminals, and wherein the sealing element defines a first sealing plug and a second sealing plug for engaging with respective openings of each of the charging terminals.
6. The charging inlet of claim 4, wherein the sealing plug comprises a cylindrical protrusion, wherein a sealing rib is formed about an outer circumference of the plug.
7. The charging inlet of claim 4, wherein the central axis of the sealing rib and the central axis of the plug are oriented on a common plane.
8. The charging inlet of claim 4, wherein the sealing element comprises a base, and a first sealing plug and a second sealing plug extending from the base.
9. The charging inlet of claim 4, wherein an end of the sealing plug is tapered about its circumference.
10. The charging inlet of claim 4, wherein the sealing plug comprises a hollow interior space open on a first end thereof for receiving the terminal in the closed position of the cover.
11. The charging inlet of claim 10, wherein the sealing plug comprises plurality of stiffening ribs defined within the hollow interior space and extending in an axial direction of the plug.
12. The charging inlet of claim 2, wherein the sealing rib is angled with respect to the sealing element such that the sealing rib simultaneously engages about its entire circumference with a circumferential wall defining the opening as the cover is moved from the open position into the closed position.
13. The charging inlet of claim 12, wherein the sealing cover is rotatably attached to the body via a hinged connection, wherein the sealing rib is angled such that it is oriented closer to the cover on a side proximate the hinged connection than on a side of the cover opposite the hinged connection.
14. The charging inlet of claim 12, wherein the sealing rib extends radially from the sealing element to a first height on a first side of sealing element and extends radially from the sealing element to a second height, greater than the first height, on a second side of the sealing element opposite the first side.
15. A sealing cover for a charging inlet of an electric vehicle (EV), comprising:
- a body having a mounting end configured to pivotally attach to the charging inlet and defining a seal-receiving space; and
- a sealing element received within the seal-receiving space of the body and comprising: a base; a sealing plug extending from the base; and an angled sealing rib formed about an outer periphery of the sealing plug, the sealing plug and sealing rib configured to form a seal with a terminal opening of the charging inlet in a closed position of the cover.
16. The sealing cover of claim 15, wherein the sealing rib extends radially from the sealing plug to a first height on a first side of sealing plug and extends radially from the sealing plug to a second height, greater than the first height, on a second side of the sealing plug opposite the first side.
17. The sealing cover of claim 15, wherein the body includes a circumferential wall defining the seal-receiving space.
18. The sealing cover of claim 15, wherein the sealing rib comprises an annular rib defined about a central axis that is not parallel with a central axis of the sealing plug.
19. The sealing cover of claim 15, wherein the sealing plug comprises a hollow interior space open on a first end thereof, wherein the sealing plug comprises plurality of stiffening ribs within the hollow interior space and extending in an axial direction of the plug.
20. The sealing cover of claim 15, wherein the sealing rib is angled such that it is oriented closer to the cover on a side proximate the mounting end than on a side of the cover opposite the mounting end.
Type: Application
Filed: Apr 22, 2021
Publication Date: Oct 27, 2022
Patent Grant number: 11590852
Applicant: TE Connectivity Services GmbH (Schaffhausen)
Inventors: Matthew Bryan Hitchcock (Middletown, PA), Aaron James de Chazal (Middletown, PA)
Application Number: 17/237,675